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Manual 62484001b Hsg200400 Gas Powered Burners English
Manual 62484001b Hsg200400 Gas Powered Burners English
I 1/8" (3,175mm) N.P.T.
DIRECTION PLUGGED TAPPING
OF FLOW PRESSURE GAGE PORT
I
'i,--y--+-
PIPE CAP
DRIP LEG
SUPPLY LINE COI\II\IECTION
TO BURNER
Figure 8
F. GAS PIPING
NOTICE: All piping must comply with state andlor
local codes. The available gas supply pressure
should be within minimum and maximum pressures
shown in the burner specifications. If the gas supply
pressure exceeds the 14" W.C. (3.5 k Pa) maximum,
an intermediate main gas regulator must be installed
ahead of the main gas manual shut off valve shown
in Figure 8.
WARNING: Failure to install the intermediate gas
regulator will result in gas leakage from burner gas
valve.
A drip leg or sediment trap must be installed in the
supply line to the burner. See Figure 8.
A pipe union shall be installed in the gas line
adjacent to, and upstream from, the main gas
manual shutoff valve. See Figure 8.
The gas supply piping to the burner should branch
off from the main gas supply line as close to the gas
meter as possible. Do not connect to the bottom of
a horizontal section. See Figure 9 for gas supply
pipe sizes.
Use new black iron pipe and malleable fittings free
of burrs and defects. Use pipe joint compound
resistant to liquefied petroleum gases.
A 1/8" (3.175mm) NPT plugged tapping accessible
for test gauge connection shall be provided
immediately upstream of the gas supply connection
for determining gas supply pressure to the burner.
Test new supply piping for leaks. CAUTION:
DURING PRESSURE TEST FOR LEAKS IN GAS
SUPPLY PIPING, THE BURNER MUST BE
DISCONNECTED TO PREVENT EXPOSING THE
COMBINATION GAS VALVE TO PRESSURES
OVER 1/2" (3447 PaG) PSIG. POSSIBLY
DAMAGING THE VALVE AND VOIDING THE
BURNER WARRANTY.
PIPE TYPE
CAPACITY - MBtu/HR (kJ)
SIZE OF GAS
OF PIPE
15 (381mm) 30 (762mm) 45 (1143mm) 90 (2286mm
3/4 Propane 400 250 200
1(19.05mm) 422000kJ) I (263750kJ) 211000kJ)
1 Natural 400 250 200
(25.4mm) (422000kJ) (263750kJ) (211000kJ)
Propane 400 350 250
I(422000kJ) 369250kJ) '263750kJ)
11/4 Natural 400 400 300
(31.75mm) (422000kJ) (422000kJ) (316500kJ)
Propane 400 400
422000kJ) 422000kJ)
11/2 Natural 400
(38.1mm) '422000kJ)
CAPACITIES SHOWN ARE FOR A TOTAL PRESSURE
DROP OF 0.3" W.C. (74.73Pa) FOR 0.5" W.C. (124.55Pa)
PRESSURE DROP, MULTIPLY CAPACITY SHOWN BY 1.3.
FOR HIGHER PERMISSIBLE PRESSURE DROPS,
CONSULT YOUR UTILITY.
SUPPLY PIPE CAPACITIES IN MBtulHR (kW)
Figure 9
G. ELECTRICAL
The installation must be wired and GROUNDED in
accordance with local codes or in their absence,
with the National Electric Code ANSI/NFPA No. 70-
1987 or latest edition.
For the 120 VAC wiring to the burner, use solid
copper conductor wire not lighter than #14 AWG. lf
a fused disconnect is used, it should be fused for a
minimum of 15 amps.
CAUTION: Each installation must include suitable
limit controls. Existing oil burner combination limit
and operating controls are normally not suitable for
gas burner use.
CAUTION: The burner is equipped with it' s own 24
VAC transformer. Do not add any 24 VAC power
consuming device in the 24 VAC control circuit of
the burner, as it could overload the transformer.
Set the room thermostat "heat anticipator" for the
totaf current draw of the 24 VAC burner operation
circuit. (HSG200 0.55 amps, HSG400 0.7 amps)
GAUTION: Label all wires orior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation.
Verify proper operation after servicing.
NOTE: lf any of the original burner wiring must be
replaced, it must be replaced with #18
AWG 105 degrees C wire or equivalent.
Section 3- Operation and Troubleshooting for
applicable burner wiring diagrams.
H. MAI N BURNER ORI FI CE SI ZI NG
AND INSTALLATION
The HSG200 and HSG400 power gas conversion
burners are approved for use with natural and
propane gas only.
The HSG200 and HSG400 burner models are
shipped labeled and orificed for natural gas. To
conveft to propane gas and/or increase BTU/HR
(kcal/Hr) input on natural or propane gas, an orifice
kit is supplied with each burner with the orifices
shown in Figure 10.
When selecting a desired BTU/HR (kcal/Hr) input,
figure 140,000 BTU' s per gallon of oil input. For
example: furnace or boiler rating of 0.75gph at 100
psig. The 0.75 x 140,000 = 105,000 BTU' s input
rate. lt may be possible to reduce the firing rate on
natural or propane gas 15% lo 20o/", as most older
appliances are oversized for the heating load.
(2.83875L x 9356 kcal
=
26559.35 kcal)
To remove or interchange main orifice discs refer to
Fi gure 15 (Page 16).
1. Remove slotted orifice cap, ltem #40, making
sure orifice cap gasket, #39, stays attached to
orifice cap and is not damaged.
2. Remove orifice spring, ltem #38, to access and
remove orifice disc. ltem #42.
3. Install desired orifice from Figure 10, making
sure it is seated flat in the orifice holder, ltem
#37.
4. Replace orifice spring and securely tighten
orifice cap against orifice cap gasket in orifice
holder.
NOTE: For
50 cycle
application
derate input
by 15%
HSG SERI ES POWER GAS CONVERSI ON BURNERS
ORI FI CE CHART
Fi gure 10
ORI FI CE
SI ZE & DRI LL
MANI FOLD PRESSURE
2.0" (498.2Pa) 3.0" (747.3Pa) 4.0" (996.4Pa)
HSG2OO NATURAL GAS
#29 - .136
(3.4544mm)
50.000 BTU
(52750kJ)
64.000 BTU {67520kJ) 76.500 BTU
(80707.5kJ
#8 - .199
(5.0546mm)
i 4,000 BTU
(78070kJ)
95.000 BTU
(100225kJ)
116.000 BTU
(122380kJ
J - .277
(7.0358mm)
112.000 BTU
(118160kJ)
138.000 BTU
(145590kJ)
164.000 BTU
(173020kJ
Q - .332
(8.4328mm)
160,000 BTU
(168800kJ)
206,000 BTU
(217330kJ)
HSG2OO L.P. GAS
#30 - 128
(3.2512mm)
49.000 BTU
(5169skJ)
58. 500 BTU
( 61717. 5kJ)
68. 200 BTU
( 71951kJ)
#27 -
j 44 (3.6576mm)
66.000 BTU
(69630kJ)
78,000 BTU
(82290kJ)
92.000 BTU {97060kJ)
#15 - . 180
( 4. 572mm)
82.000 BTU
(86510kJ)
'1
12.500 BTU
(1
1 8687.5kJ) 136.000 BTtl
(143480kJ)
D - .246
(6.2484mm)
131,000 BTU
(138205kJ)
1 87.500 BTU
(1
9781 2.5kJ) 243,000 BTU
(256365kJ)
HSG4OO NATURAL GAS
T - .358
(9.0932mm)
200.000 BTU
(211000kJ)
248.000 BTU
(261640kJ)
285000 BTU
(300675kJ)
15/ 32 - . 468
(11. 8872mm)
265,000 BTU
(279575kJ)
343.000 BTU {361865kJ)400,000 BTU
(422000kJ)
HSG4OO L.P. GAS
K - . 281
( 7. 1374mm)
190.000 BTU
(200450kJ)
242.500 BTU
(255837.5kJ
) 295.000 BTU {311225kJ)
0- .332 (8.4328mm)242,500 BTU (255837kJ)
332,500 BTU
(350787.5kJ) 400,000 BTU (422000kJ)
PAGE 5
G. ELECTRICAL
The installation must be wired and GROUNDED in
accordance with local codes or in their absence,
with the National Electric Code ANSI/NFPA No. 70-
1987 or latest edition.
For the 120 VAC wiring to the burner, use solid
copper conductor wire not lighter than #14 AWG. If
a fused disconnect is used, it should be fused for a
minimum of 15 amps.
CAUTION: Each installation must include suitable
limit controls. Existing oil burner combination limit
and operating controls are normally not suitable for
gas burner use.
CAUTION: The burner is equipped with it's own 24
VAC transformer. Do not add any 24 VAC power
consuming device in the 24 VAC control circuit of
the burner, as it could overload the transformer.
Set the room thermostat "heat anticipator" for the
total current draw of the 24 VAC burner operation
circuit. (HSG200 0.55 amps, HSG400 0.7 amps)
CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation.
Verify proper operation after servicing.
NOTE: If any of the original burner wiring must be
replaced, it must be replaced with #18
AWG 105 degrees C wire or equivalent.
Section 3- Operation and Troubleshooting for
applicable burner wiring diagrams.
H. MAIN BURNER ORIFICE SIZING
AND INSTALLATION
The HSG200 and HSG400 power gas conversion
burners are approved for use with natural and
propane gas only.
The HSG200 and HSG400 burner models are
shipped labeled and orificed for natural gas. To
convert to propane gas and/or increase BTU/HR
(kcal/Hr) input on natural or propane gas, an orifice
kit is supplied with each burner with the orifices
shown in Figure 10.
When selecting a desired BTU/HR (kcal/Hr) input,
figure 140,000 BTU's per gallon of oil input. For
example: furnace or boiler rating of 0.75gph at 100
psig. The 0.75 x 140,000 == 105,000 BTU's input
rate. It may be possible to reduce the firing rate on
natural or propane gas 15% to 20%, as most older
appliances are oversized for the heating load.
(2.83875L x 9356 kcal == 26559.35 kcal)
To remove or interchange main orifice discs refer to
Figure 15 (Page 16).
1. Remove slotted orifice cap, Item #40, making
sure orifice cap gasket, #39, stays attached to
orifice cap and is not damaged.
2. Remove orifice spring, Item #38, to access and
remove orifice disc, Item #42.
3. Install desired orifice from Figure 10, making
sure it is seated flat in the orifice holder, Item
#37.
4. Replace orifice spring and securely tighten
orifice cap against orifice cap gasket in orifice
holder.
PAGE 5
ORIFICE MANIFOLD PRESSURE
SIZE & DRILL 2.0" (498.2Pa) 3.0" (747.3Pa) 4.0" (996.4Pa)
HSG200 NATURAL GAS
#29 - .136 (3.4544mm) 50,000 BTU 152750kJl 64,000 BTU 167520kJ) 76 500 BTU 180707.5kJ)
#8 - .199 (5.0546mml 74,000 BTU 178070kJ) 95,000 BTU (1 00225kJ) 116,000 BTU (122380kJ)
J - .277 (7.0358mm) 112,000 BTU (118160kJ) 138,000 BTU 1145590kJ) 164,000 BTU 1173020kJ)
Q - .332 (8.4328mm) 160,000 BTU 1168800kJ) 206,000 BTU (217330kJ)
HSG200 L.P. GAS
#30 - .128 13.2512mm) 49,000 BTU 151695kJ) 58,500 BTU 161717.5kJ) 68,200 BTU 171951 kJ)
#27 - .144 (3.6576mm) 66,000 BTU 169630kJ) 78,000 BTU 182290kJ) 92,000 BTU 197060kJ)
#15 - .180 14572mm) 82,000 BTU 186510kJ) 112,500 BTU 1118687.5kJ) 136,000 BTU 1143480kJ)
D .246 (6.2484mm) 131,000 BTU 1138205kJ) 187,500 BTU (197812.5kJ) 243,000 BTU 1256365kJ)
HSG400 NATURAL GAS
T- .358 (9.0932mm) 200,000 BTU (211 OOOkJl 248,000 BTU 1261640kJ) 285000 BTU 1300675kJ)
15/32 - .468 (11.8872mm) 265,000 BTU (279575kJ) 343,000 BTU (361865kJ) 400,000 BTU (422000kJl
HSG400 L.P. GAS
K- .281 (7.1374mm) 190,000 BTU (200450kJ) 242,500 BTU (255837.5kJ) 295,000 BTU 1311225kJl
Q - .332 (8.4328mm) 242,500 BTU (255837kJ) 332,500 BTU (350787.5kJ) 400,000 BTU (422000kJ)
HSG SERIES POWER GAS CONVERSION BURNERS
ORIFICE CHART
Figure 10
NOTE: For
50 cycle
application
derate input
by 15%
J.
COMBINATION GAS VALVE
The 24 VAC combination gas valve serves three (3)
functions: (1) manual gas shut-off, (2) main gas
flame pressure regulator, (3) automatic electric
redundant (double seated) gas shut off. (See
Fi gur e 11)
The correct operating manifold orifice pressure range
for both natural and propane gas is 2.0" W.C.
(498. 2Pa) mi ni mum t o 4. 0" W. C. (996. aPa)
maximum. By adjusting the pressure regulator
between 2.0" W.C. (498.2Pa) and 4.0' W.C.
(996.4Pa) on either natural or propane gas, a wide
input range can be achieved with a single orifice size.
lf the desired input rating cannot be obtained within
the above manifold orifice pressure adjustment
range, the next size larger or smaller orifice should be
used. (Referto orifice chart Fig. 10.)
PRESSURE REGULATOR ADJ USTMENT
The combination gas valve pressure regulator,
which has an outlet pressure setting range of
PRESSURE
REGUI-ATOR
approximately 2.0" W.C. (498.2Pa) to 4.0" W.C.
(996.4Pa) is factory set at 3.5' W.C (871.85Pa).
When pressure adjustment is required for setting
input capacity with a selected orifice from Figure 10,
remove the regulator cap for access to the slotted
adjustment screw. Turning the screw counter
clockwise reduces manifold orifice pressure,
clockwise increases the pressure.
NOTE: MANIFOLD PRESSURE ADJUSTMENTS
CAN ONLY BE MADE WI TH THE
BURNER RUNNI NG AND THE GAS ON.
The 1/8" (3.175mm) NPT pressure tap for orifice
manifold pressure measurement is located on the
outlet side of the combination gas valve. Use a "u"
tube manometer or dial type pressure gauge,
scaled from "0" zero lo 15.0' W.C. (3736.5Pa) to
read pressure (See Figure 11).
PRESSURE
REGULATOR
1/8" (3.175mm)
NPT
PRESSURE TAP PLUG
HSG 2OOI4OO GAS VALVE
HONEYWELL VR83O5
t /ANUAL CONTROL
KNOB (SHOWN tN
oFF POSmON)
HSG4OO GAS VALVE
ROBERTSHAW TOOO DERHC
Fi gure 11
PAGE 6
I. COMBINATION GAS VALVE
The 24 VAC combination gas valve serves three (3)
functions: (1) manual gas shut-off, (2) main gas
flame pressure regulator, (3) automatic electric
redundant (double seated) gas shut off. (See
Figure 11)
The correct operating manifold orifice pressure range
for both natural and propane gas is 2.0" WC.
(498.2Pa) minimum to 4.0" W.C. (996.4Pa)
maximum. By adjusting the pressure regulator
between 2.0" WC. (498.2Pa) and 4.0" WC.
(996.4Pa) on either natural or propane gas, a wide
input range can be achieved with a single orifice size.
If the desired input rating cannot be obtained within
the above manifold orifice pressure adjustment
range, the next size larger or smaller orifice should be
used. (Refer to orifice chart Fig. 10.)
J. PRESSURE REGULATOR ADJUSTMENT
The combination gas valve pressure regulator,
which has an outlet pressure setting range of
approximately 2.0" WC. (498.2Pa) to 4.0" WC.
(996.4Pa) is factory set at 3.5" WC (871.85Pa).
When pressure adjustment is required for setting
input capacity with a selected orifice from Figure 10,
remove the regulator cap for access to the slotted
adjustment screw. Turning the screw counter
clockwise reduces manifold orifice pressure,
clockwise increases the pressure.
NOTE: MANIFOLD PRESSURE ADJUSTMENTS
CAN ONLY BE MADE WITH THE
BURNER RUNNING AND THE GAS ON.
The 1/8" (3.175mm) NPT pressure tap for orifice
manifold pressure measurement is located on the
outlet side of the combination gas valve. Use a "u"
tube manometer or dial type pressure gauge,
scaled from "0" zero to 15.0" WC. (3736.5Pa) to
read pressure (See Figure 11).
PRESSURE
REGULATOR
MANUAl CONTROL
KNOB (SHOWN IN
OFF pOSmON)
1/8" (3.175mm) NPT
PRESSURE TAP
PLUG
INLET
MANUAL CONTROL
KNOB (SHO'olN IN
orr POSITION)
118" (3.175mm) NPT
PRESSURE TAP PLUG
HSG400 GAS VALVE
ROBERTSHAW 7000 DERHC
HSG 200/400 GAS VALVE
HONEYWELL VR8305
Figure 11
PAGE 6
SECTION II
INITIAL START UP
1. NOTE: Read t he appl i cabl e sequence of
burner/primary gas control operation in
Section 3 Operation and Troubleshooting
before proceeding.
2. Depress the combination gas valve manual control
knob and turn to "OFF" position.
3. Adjust the primary air and off-cycle damper to the
start up settings shown in Figure 12Aand 128.
4. On new gas line installations, air may be trapped in
t he l i ne, t he burner may experi ence several
lockouts until all the air is purged from the lines.
5. Turn on the main electrical power and set the
thermostat or operation control to call for heat.
Al l ow t he burner t o run a MI NI MUM of 5 mi nut es t o
purge combustion chamber and appliance heat
exchanger.
6. Set the thermostat or operating control below room
temperature, shutting the burner "OFF" 1 minute to
RESET the primary control.
7. Depress the combination gas valve manual control
now and turn to "ON" position.
8. Set the thermostat or operating control to call for
heat. The burner will start and go through the
applicable sequence of burner/primary gas control
operation, refer to step 1.
9. Once burner is running adjust the orifice manifold
pressure regulator as described in paragraph J -
Pressure Regu lator Adjustment.
10. A more accurate BTU (kW) input can be determined
by using the NATURAL gas service meter with the
burner only on (all other gas appliances should be
off). The hand on the gas meter dialwith the lowest
cubic feet valve (fastest revolving dial), should be
clocked for one complete revolution and use the
following formula.
3600 x cubic ft. (m3)pre revolution x btu (kW)valve/cub ic fl (m3)= BTU/HR (kWH0
seconds oer revolulion
EXAMPLE: 3600 x 1 x 1000
(.2931k$ = 300,000 BTU/HR (87.93 kWHB)
12
11. After the desired input has been obtained, re-adjust
the primary air damper open or closed to visually
obtain a blue flame with well defined orange or
yellow tips for natural gas, or well defined yellow tips
for propane gas.
12. After the burner has been in operation for at least 10
minutes, assuring combustion chamber and heat
exchanger are fully warmed, take combustion
analysis flue gas samples
just
ahead of the draft
control in the flue pipe.
NOTE: ALWAYS USE RELIABLE COMBUSTION
TEST I NSTRUMENTS. BEI NG
PROFICIENT IN THE USE OF THESE
I NSTRUMENTS AND I NTERPRETI NG
THEIR DATA IS NECESSARY FOR SAFE,
RELI ABLE AND EFFI CI ENT BURNER
OPERATION.
13. Perform the following combustion analysis. All
adjustments below must be made with the following
instruments: draft gauge, 02 or CO2 analyze and
CO tester.
A. Adjust the primary air damper to provide about
257o excess combustion air. Confirm this by
checking the flue gas for its FREE OXYGEN
(Oz) or CARBON DIOXIDE (COz) PERCEN-
TAGES with a test instrument. Free oxygen
should be about 4.5"/o, or carbon dioxide should
be about 9.5% for natural gas, 12.1"/" for
propane gas.
B. CARBON MONOXIDE - Should be checked for
its presence in the flue gas. This percentage
should not exceed .04/" (or 400 PPM).
C. NOTE: Check overfire draft and adjust to
NEGATIVE -.01
(2.491Pa) to -.02
(4.982Pa)
inches w/c during burner operation.
PAGE 7
SECTION II
INITIAL START UP
1. NOTE: Read the applicable sequence of
burner/primary gas control operation in
Section 3 Operation and Troubleshooting
before proceeding.
2. Depress the combination gas valve manual control
knob and turn to "OFF" position.
3. Adjust the primary air and off-cycle damper to the
start up settings shown in Figure 12A and 12B.
4. On new gas line installations, air may be trapped in
the line, the burner may experience several
lockouts until all the air is purged from the lines.
5. Turn on the main electrical power and set the
thermostat or operation control to call for heat.
Allow the burner to run a MINIMUM of 5 minutes to
purge combustion chamber and appliance heat
exchanger.
6. Set the thermostat or operating control below room
temperature, shutting the burner "OFF" 1 minute to
RESET the primary control.
7. Depress the combination gas valve manual control
now and turn to "ON" position.
8. Set the thermostat or operating control to call for
heat. The burner will start and go through the
applicable sequence of burner/primary gas control
operation, refer to step 1.
9. Once burner is running adjust the orifice manifold
pressure regulator as described in paragraph J -
Pressure Regulator Adjustment.
10. A more accurate BTU (kW) input can be determined
by using the NATURAL gas service meter with the
burner only on (all other gas appliances should be
off). The hand on the gas meter dial with the lowest
cubic feet valve (fastest revolving dial), should be
clocked for one complete revolution and use the
following formula.
3600 xcubic ft. (m
3
)pre revolution xbtu (kW) valve/cub ic ft (m
3
) =BTUIHR (kW/Hr)
seconds per revolution
EXAMPLE: 3600 x 1x 1000 1.2931 kW) =300,000 BTU/HR (87.93 kW/HR)
12
11. After the desired input has been obtained, re-adjust
PAGE 7
the primary air damper open or closed to visually
obtain a blue flame with well defined orange or
yellow tips for natural gas, or well defined yellow tips
for propane gas.
12. After the burner has been in operation for at least 10
minutes, assuring combustion chamber and heat
exchanger are fully warmed, take combustion
analysis flue gas samples just ahead of the draft
control in the flue pipe.
NOTE: ALWAYS USE RELIABLE COMBUSTION
TEST INSTRUMENTS. BEING
PROFICIENT IN THE USE OF THESE
INSTRUMENTS AND INTERPRETING
THEIR DATA IS NECESSARY FOR SAFE,
RELIABLE AND EFFICIENT BURNER
OPERATION.
13. Perform the following combustion analysis. All
adjustments below must be made with the following
instruments: draft gauge, 02 or C02 analyze and
CO tester.
A. Adjust the primary air damper to provide about
25% excess combustion air. Confirm this by
checking the flue gas for its FREE OXYGEN
(0
2
) or CARBON DIOXIDE (C02) PERCEN-
TAGES with a test instrument. Free oxygen
should be about 4.5%, or carbon dioxide should
be about 9.5% for natural gas, 12.1 % for
propane gas.
B. CARBON MONOXIDE - Should be checked for
its presence in the flue gas. This percentage
should not exceed .04% (or 400 PPM).
C. NOTE: Check overfire draft and adjust to
NEGATIVE -.01 (2.491 Pa) to -.02 (4.982Pa)
inches w/c during burner operation.
D. The flue gas temperature should be between
325"F (162.78"C) and 550"F (287.78"C)tor
domestic gas conversion burners. Higher flue
gas t emperat ures i ndi cat e overf i ri ng or
excessive draft through the appliance. Lower
flue gas temperatures may cause excessive
condensation and indicate underfiring. Consult
your local utility or the appliance manufacturer
for acceptable flue gas temperatures.
CAUTION: lF THE BURNER BTU/HR (kWHr)
INPUT IS CHANGED. REPEAT STEP 13
3/8" (9.525mm)
HSG2OO SETAT NO. 1
HSG4OO SETAT NO. 1 1/2
OFF CYCLE DAMPER
SETTING
Fi gure 12A
14. FILL OUT THE INSTALLATION COMBUSTION
DATA TAG AND AFFIX IT TO THE BURNER OR
CONVERTED APPLIANCE.
SUGGESTION: All new installations should be
reinspected for proper combustion and burner
operation after one or two weeks of normal
operation.
For subsequent normal starting and shut off
procedure, refer to the "Consumer lnstructions" in
the back of this manual or the instruction plate
attached to the burner.
HSG2OO SET AT NO.2
HSG4OO SET AT NO.4
PRI MARY AI R
SETTING
Fi gure 128
IMPORTANT
THESE SETTI NGS ARE FOR I NI TI AL STARTUP ONLY AND MUST BE
READJUSTED FOR COMBUSTI ON EFFI CI ENCY.
,ssK
Fi gure 12C
PAGE 8
D. The flue gas temperature should be between
325'F (162.78'C) and 550'F (287.78'C)for
domestic gas conversion burners. Higher flue
gas temperatures indicate overfiring or
excessive draft through the appliance. Lower
flue gas temperatures may cause excessive
condensation and indicate underfiring. Consult
your local utility or the appliance manufacturer
for acceptable flue gas temperatures.
CAUTION: IF THE BURNER BTU/HR (kWlHr)
INPUT IS CHANGED, REPEAT STEP 13
14. FILL OUT THE INSTALLATION COMBUSTION
DATA TAG AND AFFIX IT TO THE BURNER OR
CONVERTED APPLIANCE.
SUGGESTION: All new installations should be
reinspected for proper combustion and burner
operation after one or two weeks of normal
operation.
For subsequent normal starting and shut off
procedure, refer to the "Consumer Instructions" in
the back of this manual or the instruction plate
attached to the burner.
3/8" (9.525mm)
HSG200 SET AT NO.1
HSG400 SET AT NO.1 1/2
OFF CYCLE DAMPER
SETTING
Figure 12A
HSG200 SET AT NO.2
HSG400 SET AT NO.4
PRIMARY AIR
SETTING
Figure 12B
IMPORTANT
THESE SETTINGS ARE FOR INITIAL STARTUP ONLY, AND MUST BE
READJUSTED FOR COMBUSTION EFFICIENCY.
r----1J.18(JJ4.77mm) REF.. ----j
FlANGE NOT SHOWN
7.01(178.05mm) REF.
Figure 12C
7.88('95.07mm) REF.
15.2J(J86.84mm)
REF
PAGE 8
SECTION III
OPERATION AND TROUBLESHOOTING
SEQUENCE OF OPERATI ON - HSG SERI ES POWER GAS
CONVERSI ON BURNER UTI LI ZI NG HONEYWELL S89F
GAS PRIMARY P/N 62759-002 WBUILT IN 30 SECOND PREPURGE
On a call for heat, voltage (24V) is applied to motor start
relay and air switch. Once the fan motor reaches
operating rpm combustion air pressure is sensed by the
air proving switch and closes the switch contacts
energizing the S89F gas primary control.
THE S89F gas primary control has an internal 30
second prepurge timer. After the initial 30 second
prepurge, an internal 8 second safe start check of the
S89F wi l l commence. Once t hi s i s successf ul l y
completed, the S89F simultaneously energizes the gas
valve and ignition transformer. Gas flows and the
transformer produces an approximate 7300 volt spark
end point grounded at the burner head establishing
main burner flame.
At the start of each heat cycle, there is a trial for ignition
period of four (4) seconds duration. Normally, burner
flame will be established before the end of this period.
Once the flame is established, sparking will cease and
the flame rod will provide flame monitoring to the S89F
gas control primary for the remainder of the heat cycle.
lf the flame should be extinguished during the heat
cycle, the S89F gas control primary will go into the 30
second prepurge and 8 second safe start check, then
re-energize the gas valve and ignition transformer in an
attempt to establish the main burner flame. lf this does
not occur within the 4 second trial for ignition period, the
S89F gas primary control will go into lockout de-
energizing the gas valve and ignition transformer.
To restart the system, the main power or thermostat
must be de-energized momentarily, then re-energized.
lf at any time during the heat cycle, there is an
insufficient supply of combustion air to the burner, the
air switch will open, putting the system into lockout
closing the gas valve.
BURN ER
GAS PRI MARY
HSG POWER GAS
WITH HONEYWELL S89F
24VAC
TRANS.
N WI RE NUT
BURNER GND
24VAC
YL-__--1--l
t <l
YL--------lJl
REOUNOANT
GAS VALVE
I GNI TI ON ROD
IF ANY OF IHE ORIGIML WIRE.
AS SUPPUEO $TH THE APPLINCE,
MUST 8E REPLACED. IT VUSI EE
REPLACED Y{ITH TYPE AWM ISGA
I O5' C WI RE OR EOUI VALENT.
PAGE 9
lScHEMATiel
SECTION III
OPERATION AND TROUBLESHOOTING
SEQUENCE OF OPERATION - HSG SERIES POWER GAS
CONVERSION BURNER UTILIZING HONEYWELL S89F
GAS PRIMARY PIN 62759-002 W/BUILT IN 30 SECOND PREPURGE
On a call for heat, voltage (24V) is applied to motor start
relay and air switch. Once the fan motor reaches
operating rpm combustion air pressure is sensed by the
air proving switch and closes the switch contacts
energizing the S89F gas primary control.
THE S89F gas primary control has an internal 30
second prepurge timer. After the initial 30 second
prepurge, an internal 8 second safe start check of the
S89F will commence. Once this is successfully
completed, the S89F simultaneously energizes the gas
valve and ignition transformer. Gas flows and the
transformer produces an approximate 7300 volt spark
end point grounded at the burner head establishing
main burner flame.
At the start of each heat cycle, there is a trial for ignition
period of four (4) seconds duration. Normally, burner
flame will be established before the end of this period.
Once the flame is established, sparking will cease and
the flame rod will provide flame monitoring to the S89F
gas control primary for the remainder of the heat cycle.
If the flame should be extinguished during the heat
cycle, the S89F gas control primary will go into the 30
second prepurge and 8 second safe start check, then
re-energize the gas valve and ignition transformer in an
attempt to establish the main burner flame. If this does
not occur within the 4 second trial for ignition period, the
S89F gas primary control will go into lockout de-
energizing the gas valve and ignition transformer.
To restart the system, the main power or thermostat
must be de-energized momentarily, then re-energized.
If at any time during the heat cycle, there is an
insufficient supply of combustion air to the burner, the
air switch will open, putting the system into lockout
closing the gas valve.
HSG POWER GAS BURNER
WITH HONEYWELL S89F GAS PRIMARY
L2
MOTOR MOTOR
IRELAYI INTEGRAL
IGN. TRANS.
RELAY
I I
I I
THERMOSTAT 24VAC TRANS.
I COIL I
L..::J
AIR
II
SWITCH
1 G 24 24 V V
N VAC VAG A A
= 0 L L
I LADDER I
-
S
V V
E
E E
REDUNDANT
N
GAS VALVE
PART NO. 62488-004
FLAME SENSOR I S-B9-F
24VAC
YL --------r=n
YL-------UJ
REDUNDANT
GAS VALVE
S-89-F
8w
BURNER GND
VALVE
VALVE
24VAC SENS
,------'1-BRN 24VAC
GRN K
FLAME SENSOR
WHT
BLK BLU IGNITION
1\ WIRE NUT
24VAC
TRANS.
IGNITION ROO
:e-__ =7(I---'-----"'v::s
MUST BE REPLACED. IT MUST BE
REPLACED WITH TYPE AWM 18CA
105" C WIRE OR EQUIVALENT.
ISCHEMATlcl
'-----==--- ---.J
PAGE 9
SEQUENCE OF OPERATI ON - HSG SERI ES
POWER GAS CONVERSI ON BURNER UTI LI ZI NG
HONEYWELL S89E GAS PRIMARY P/N 62758.002 W/ EXTERNAL
30 SECOND PREPURGE TIMER P/N 62388-001 AND RESISTOR P/N 62530-001
On a call for heat, voltage (24V) is applied to the motor
start relay and air switch. The motor relay pulls in the
motor. After the motor reaches speed, the combustion
air blower closes the air proving switch contacts,
energizing the external30 second prepurge timer. After
the 30 second prepurge timing, the S89E is energized.
The S89E gas primary control has an internal 8 second
safe start check. After the initial 30 second prepurge
provided by the external timer, the S89E gas primary
control is energized, the I second safe start check will
commence. Once this is accomplished, the S89E
activates the gas valve allowing gas to flow to the burner
head. Simultaneously, the S89E control energizes the
ignition transformer, producing an approximate 7300
volt spark end point grounded at the burner head,
establishing main burner flame.
At the start of each heat cycle, there is a trial for ignition
period of four (4) seconds duration. Normally, burner
flame will be established before the end of this period.
Once the flame is established, sparking will cease and
the flame rod will provide flame monitoring to the S89E
gas primary control for the remainder of the heat cycle.
When utilizing the S89E gas primary control with the
eternal 30 second prepurge timer, a 10K ohm resistor is
wired in
parallel
between the outout terminal of the 30
second prepurge timer and the input terminal to the
S89E gas primary control. The function of this resistor
is to keep a load on the output terminal of the external
30 second prepurge timer, after the initial call for heat
and 30 second start prepurge and 8 second safe start
check.
This promotes simultaneous re-ignition of the main
burner flame after the S89E' s 8 second safe start check,
overriding the 30 second prepurge. This is desirable in
oven or similar applications where temperatures cannot
vary drastically.
Should the flame be extinguished during the heat cycle,
the S89E primary ignition control will go into the I
second safe staft check after which time it will re-
energize the gas valve and ignition transformer in an
attemot to re-establish the main burner flame. lf this
does not occur within the 4 second trial for ignition
period, the S89E gas primary control will go into lockout
de-energizing the gas valve and ignition transformer. To
restart the system, the main power or thermostat must
be de-energized momentarily, then re-energized. lf at
any time during the heat cycle, there is insufficient
supply of combustion air to the burner, the air switch
contacts will open, putting the system into lockout
closing the gas valve.
AIR PREPURGE
SWITCH TIMER
N WIRE NUT
BURNER CNO
HSG POWER GAS BURNER
WI TH HONEYWELL S89E GAS PRI MARY
24VAC
YL---_-F-l
t {l
YL------lJl
REDUNOANT
GAS VALVE
s- E9- E
IF ANY OF THE ORIGINAL WIRE,
AS SUPPL]ED W]TH THE APPLIANCE.
MUST AE REPUCED, I T VUST BE
REPLACEO WITH TYPE AWM 1AGA
1O5' C WI RE OR EOUI VALNT.
z
e
LI MI T/ @
I i THERMOSTAT
: 24VAC
TRANS.
l ScHEMATIcl
PAGE 10
SEQUENCE OF OPERATION - HSG SERIES
POWER GAS CONVERSION BURNER UTILIZING
HONEYWELL S89E GAS PRIMARY PIN 62758-002 WI EXTERNAL
30 SECOND PREPURGE TIMER PIN 62388-001 AND RESISTOR PIN 62530-001
On a call for heat, voltage (24V) is applied to the motor
start relay and air switch. The motor relay pulls in the
motor. After the motor reaches speed, the combustion
air blower closes the air proving switch contacts,
energizing the external 30 second prepurge timer. After
the 30 second prepurge timing, the S89E is energized.
The S89E gas primary control has an internal 8 second
safe start check. After the initial 30 second prepurge
provided by the external timer, the S89E gas primary
control is energized, the 8 second safe start check will
commence. Once this is accomplished, the S89E
activates the gas valve allowing gas to flow to the burner
head. Simultaneously, the S89E control energizes the
ignition transformer, producing an approximate 7300
volt spark end point grounded at the burner head,
establishing main burner flame.
At the start of each heat cycle, there is a trial for ignition
period of four (4) seconds duration. Normally, burner
flame will be established before the end of this period.
Once the flame is established, sparking will cease and
the flame rod will provide flame monitoring to the S89E
gas primary control for the remainder of the heat cycle.
When utilizing the S89E gas primary control with the
eternal 30 second prepurge timer, a 10K ohm resistor is
wired in parallel between the output terminal of the 30
second prepurge timer and the input terminal to the
S89E gas primary control. The function of this resistor
is to keep a load on the output terminal of the external
30 second prepurge timer, after the initial call for heat
and 30 second start prepurge and 8 second safe start
check.
This promotes simultaneous re-ignition of the main
burner flame after the S89E's 8 second safe start check,
overriding the 30 second prepurge. This is desirable in
oven or similar applications where temperatures cannot
vary drastically.
Should the flame be extinguished during the heat cycle,
the S89E primary ignition control will go into the 8
second safe start check after which time it will re-
energize the gas valve and ignition transformer in an
attempt to re-establish the main burner flame. If this
does not occur within the 4 second trial for ignition
period, the S89E gas primary control will go into lockout
de-energizing the gas valve and ignition transformer. To
restart the system, the main power or thermostat must
be de-energized momentarily, then re-energized. If at
any time during the heat cycle, there is insufficient
supply of combustion air to the burner, the air switch
contacts will open, putting the system into lockout
closing the gas valve.
HSG POWER GAS BURNER
WITH HONEYWELL S89E GAS PRIMARY
24VAC
REDUNDANT
GAS VALVE
24VAC TRANS.
L2
IGN. TRANS.
S-89-E
S
E
MOTOR
N
FLAME SENSOR
I LADDER I
RESISTOR
THERMOSTAT
L1
MOTOR
,..----.
: H'----,---=--=--=-----{
: RELAY:
I I
I I
I I
I I
I I I., .J
LIMIT
AIR ,..-__,/1/'1/1, -----, -1
SWITch liMIY/
CONTROLLER
I COIL,
f--f-{' )-;'------------------i
PART NO. 62488-003
S-89-E
24VAC
YL ------r=n
YL---UJ
REDUNDANT
GAS VALVE
BLU
BRN
GRN
MOTO
VALVE
24VAC SENS
24VAC
GND(24VAC) 8LK
WHT
BlK BLU ICNlT10N
BURNER GND
IGNITiON ROO
IF ANY OF THE ORIGINAl WIRE.
AS SuPPLIED WITH THE APPUANCE.
MUST BE REPLACED, IT t.4UST BE
REPLACED WITH TYPE AWM 18GA
lOS" C WIRE OR EQUIVAlENT.
/\ WIRE NUT
AIR PREPURGE
SWITCH TIMER
RESISTOR
YL.-."" I \I \ I \
YL
24VAC
TRANS.
ISCHEMATlcl
'----'==-- ....J
PAGE 10
FLAME SENSI NG
The Honeywell S89 series primary ignition controls
utilize the flame current rectification principal for main
burner flame sensing.
The flame rectification phenomenon occurs as follows.
The ignited gas flame causes the immediate
atmosphere around the flame to become ionized (gas
atoms become electrically charged). The ionization
causes the atmosphere around the flame to become
electrically conductive. An AC voltage output from the
control sensing circuit is routed through the flame
sensor probe. When the sensor probe and the burner
head are both in contact with a properly adjusted flame,
the burner head with its larger surface attracts more free
electrons, thus becoming negatively charged. The
sensor probe with its small surface area gives up free
electrons, thus becoming positively charged. The free
electrons from the AC voltage in the sensor probe flow
PROBE DI M
I GNI TER
' t
5/ 8 41. 2Emm
SENSOR1 1/ 4 J1. 75mm)
through the ionized gas flame to the grounded burner
head. As the AC current passes through the gas flame,
it is rectified into a DC current flowing back to the
grounded side of the sensing circuit. The flame in
actuality is a switch. When the flame is present, the
switch is closed allowing current to flow through the
sensing circuit of the control. When no flame is present,
the switch is open with no current flowing through the
sensing circuit of the control.
The DC current flow is measured in units called DC
microamperers. A steady DC microamp current of .8
minimum (and steady) or higher through the sensing
circuit of the primary ignition control is sufficient to keep
the burner running without a safety lockout. See Figure
13 for sensor probe and electrode dimensional settings,
Figure 14 for flame current measurement.
13/16 Q0,64nn) REF,
F- 3t +
|
{l s. 0smm)
( 2, 381mn)
1
/
16 ( 1. 588mm)
Fi gure 13
S89 FLAME CURRENT MEASUREMENT
Fi gure 14
FLAME SENSOR CURRENT CHECK-USE pA SCALE
TO
SENSOR
MULTIPURPOSE METER
DISCONNECT
WIRE FFOM
SENSE
TEBMINAL
RED(+
BLACK(-)
0.8 uA DC MINMUM
(AND STEADY)
O
\'C
PAGE 11
FLAME SENSING
The Honeywell S89 series primary ignition controls
utilize the flame current rectification principal for main
burner flame sensing.
The flame rectification phenomenon occurs as follows.
The ignited gas flame causes the immediate
atmosphere around the flame to become ionized (gas
atoms become electrically charged). The ionization
causes the atmosphere around the flame to become
electrically conductive. An AC voltage output from the
control sensing circuit is routed through the flame
sensor probe. When the sensor probe and the burner
head are both in contact with a properly adjusted flame,
the burner head with its larger surface attracts more free
electrons, thus becoming negatively charged. The
sensor probe with its small surface area gives up free
electrons, thus becoming positively charged. The free
electrons from the AC voltage in the sensor probe flow
through the ionized gas flame to the grounded burner
head. As the AC current passes through the gas flame,
it is rectified into a DC current flowing back to the
grounded side of the sensing circuit. The flame in
actuality is a switch. When the flame is present, the
switch is closed allowing current to flow through the
sensing circuit of the control. When no flame is present,
the switch is open with no current flowing through the
sensing circuit of the control.
The DC current flow is measured in units called DC
microamperers. A steady DC microamp current of .8
minimum (and steady) or higher through the sensing
circuit of the primary ignition control is sufficient to keep
the burner running without a safety lockout. See Figure
13 for sensor probe and electrode dimensional settings,
Figure 14 for flame current measurement.
"A"
13/16 (20,64MM) REF.
~ 3 / 4
I <l9,05MM)
-,
Figure 13
FLAME SENSOR CURRENT CHECK-USE jJA SCALE
@
_ VAlVE
- 24V
- ~ _ GHO
@
@
@
TO
SENSOR
BLACK(-)
0.8 ~ A DC MINMUM
(AND STEADY)
S89 FLAME CURRENT MEASUREMENT
Figure 14
PAGE 11
HSG SERIES WITH A HONEYWELL S89E, S89F PRIMARY IGNITION CONTROLS
TROUBLE SHOOTING GUIDE
MOTOR DOES NOT START
Replace 24 volt AC
20 VA Transformer
2. Check tor 24 volts AC between terminals 1 and 3
on motor start relay.
3. Check for 120 volts AC between terminal 2 on
motorstart relay and neutral line.
4. Check electrical wiring and connections.
1. Check for blower clearance.
2. Lubricate motor bearings.
5. Does motor shaft turn freely?
Check the low voltage transformer tor 24 volt output
between terminal 3 on the motor start relay either
of the' T' terminals on the control box.
IGNITION ARC ESTABLISHED
-
NO FLAME
l .
Reset Control - Motor starts
-
Completes 30 second prepurge cycle, 8 second safe start check and trial for
ignition, 4 seconds Honeywell series. NOTE: The burner motor will continue to
operate during the lock out mode when the thermostat circuit is called for burner operation.
2. Check for correct ori fi ce/ai r setti ng rel ati onshi p (see fi gures 10, 12A, 128, and 12C).
In order for the following functional test to be made,
the control must be reset and the tests monitored dur-
ing the 4 second Honeywell series trial for ignition peri-
od that occurs at the END of the 30 second prepurge
and I second safe start check cycle.
3. Check tor 24 volts AC at gas valve terminals. Check electrical wiring and
connections. Be sure leads
are on correct gas valve ter-
mi nal s
4. Make sure leads are on the correct gas valve
termi nal s
pressure
PAGE 12
HSG SERIES WITH A HONEYWELL S89E, S89F PRIMARY IGNITION CONTROLS
TROUBLE SHOOTING GUIDE
MOTOR DOES NOT START
I. Check the low voltage transformer for 24 volt output
between terminal 3 on the motor start relay either
of the "T' terminals on the control box.
2. Check for 24 volts AC between terminals 1 and 3
on motor start relay.
3. Check for 120 volts AC between terminal 2 on
motorstart relay and neutral line.
4. Check electrical wiring and connections.
Check electrical wiring and
connections.
Check electrical wiring and
connections.
Check electrical wiring and
connections.
Replace 24 volt AC
20 VA Transformer
Replace motor
start relay.
Replace motor
start relay.
5. Does motor shaft turn freely?
6.
IGNITION ARC ESTABLISHED - NO FLAME
OK
1. Check for blower clearance.
2. Lubricate motor bearings.
Reset Control - Motor starts - Completes 30 second prepurge cycle, 8 second safe start check and trial for
ignition, 4 seconds Honeywell series. NOTE: The burner motor will continue to
operate during the lock out mode when the thermostat circuit is called for burner operation.
2. Check for correct orifice/air setting relationship (see figures 10, 12A, 12B, and 12C).
In order for the following functional test to be made,
the control must be reset and the tests monitored dur-
ing the 4 second Honeywell series trial for ignition peri-
od that occurs at the END of the 30 second prepurge
and 8 second safe start check cycle.
3. Check for 24 volts AC at gas valve terminals.
4. Make sure leads are on the correct gas valve
terminals
Check for correct manifold regulated pressure
(see figure 10).
Check electrical wiring and
connections. Be sure leads
are on correct gas valve ter-
minals
Replace primary
ignition control.
6.
PAGE 12
NO IGNITION ARC ESTABLISHED
Control
.
Motor starts
- Completes 30 second prepurge
start check series.
.
Gas valve opens, regulating adequate gas pressure.
.
No flame established - Primary control locks out after 4 secondHoneywell series trial for
In order for the following functional test to be made,
the control must be reset and the tests monitored dur-
ing the 4 second Honeywell series trial for ignition that
occurs at the end of the 30 second prepurge cycle,
and I second safe start check.
Check tor 12O volts AC between the neutral line
and the
function
of the blue primary control lead
and the black ignition transformer lead.
Gheck electrical wiring and connections.
Check the flame sensing circuit for (1) grounded
flamerod. (2) Damage to flamerod lead insula-
tion. NOTE: Make sure that the flamerod circuit
and/or primary control is moisture-free.
3. Check electrical wiring and connections.
4. Check high voltage lead and connection to ignition
electrode rod.
Inspect ignition electrode for cracked insulator and
correct spark gap (Fig. 13).
NO IGNITION
-
NO GAS VALVE
1. Reset Control - Motor starts - After 30 second prepurge cycle and 8 second safe start check. Motor continues
to run but flame is not established.
In order to perform the following functional tests, the
primary control must be reset and the tests monitored
during the 4 second Honeywellseries trialfor ignition
that occurs at the end of the 30 second prepurge cycle
and 8 second safe start check.
2. Check tor 24 volts AC atthe 24 volt primary control
input terminals labeled yellow and brown.
Replace primary ignition control.
3. Check air proving switch for:
a. Any impairment that would keep it from
closing or opening.
b. Electrical continuity; switch is normally open.
c. Replace switch as necessary.
4. Check (when applicable) external 30 second
prepurge timer (jumper around timer from air
switch). Should primary ignition control
become energized, replace timer.
PAGE 13
NO IGNITION ARC ESTABLISHED
1. Reset Control Motor starts - Completes 30 second prepurge cycle, 8 second safe start check series.
Gas valve opens, regulating adequate gas pressure.
No flame established - Primary control locks out after 4 second Honeywell series trial for
ignition periods.
0
In order for the following functional test to be made,
the control must be reset and the tests monitored dur-
ing the 4 second Honeywell series trial for ignition that
occurs at the end of the 30 second prepurge cycle,
and 8 second safe start check.
h..
2. Check for 120 volts AC between the neutral line
Check electrical wiring and connections.
and the junction of the blue primary control lead
and the black ignition transformer lead.
h..
2. Check for 24 volts AC at the 24 volt primary control
Replace primary ignition control.
I
input terminals labeled yellow and brown.